Traction battery pack assembling method

Abstract

A battery pack assembly method includes compressing at least one cell stack, inserting the at least one cell stack into a cell-receiving opening of an enclosure structure, and pushing at least one cell of the at least one cell stack out of the enclosure structure using a pusher. Another traction battery pack assembly method includes moving a cell stack into an enclosure structure from a compression fixture that compresses the cell stack. The cell stack includes a plurality of battery cells. After the moving, the method compresses the cell stack using the enclosure structure. The method then includes establishing electrical connections between the battery cells of the cell stack, and testing the electrical connections prior to securing a busbar to the cell stack.

What is claimed is: 
     
       1. A battery pack assembly method, comprising:
 compressing at least one cell stack within a compression fixture; 
 displacing the at least one cell stack from within the compression fixture while inserting the at least one cell stack into a cell-receiving opening of an enclosure structure; and 
 when the at least one cell stack is within the enclosure structure and outside the compression fixture, pushing at least one cell of the at least one cell stack out of the enclosure structure using a pusher. 
 
     
     
       2. The method of  claim 1 , wherein the compressing includes compressing a first cell stack and a second cell stack, wherein the inserting comprises simultaneously inserting both the first cell stack and the second cell stack into the enclosure structure. 
     
     
       3. The method of  claim 2 , further comprising simultaneously inserting the first cell stack together with the second cell stack using a plunger that contacts both the first cell stack and the second cell stack during the inserting. 
     
     
       4. The method of  claim 2 , wherein the first cell stack and the second cell stack are spaced from each other during the inserting. 
     
     
       5. The method of  claim 2 , further comprising compressing the first cell stack using a first compression fixture, and compressing the second cell stack using second compression fixture that is different than the first compression fixture. 
     
     
       6. The method of  claim 1 , wherein the enclosure structure is an enclosure halo. 
     
     
       7. The method of  claim 1 , wherein the compressing of the at least one cell stack is along an axis, wherein the inserting moves the at least one cell stack relative to the enclosure structure in a direction that is perpendicular to the axis. 
     
     
       8. The method of  claim 1 , further comprising after the inserting, applying a compressive force to the at least one cell stack with the enclosure structure. 
     
     
       9. The method of  claim 1 , wherein the enclosure structure circumferentially surrounds the at least one cell stack after the inserting. 
     
     
       10. The method of  claim 1 , wherein the pushing is in response to an inspection of the at least one cell stack after the inserting. 
     
     
       11. The method of  claim 10 , wherein the inspection includes an inspection of a weld. 
     
     
       12. The method of  claim 11 , wherein the weld is a busbar weld. 
     
     
       13. The method of  claim 1 , wherein the at least one cell stack includes a first number of individual cells, wherein the at least one cell that is pushed by the pusher comprises a second number of individual cells that is fewer than the first number of individual cells. 
     
     
       14. A battery pack assembly method, comprising:
 compressing at least one cell stack; 
 inserting the at least one cell stack into a cell-receiving opening of an enclosure structure; and 
 pushing at least one cell of the at least one cell stack out of the enclosure structure using a pusher, 
 wherein the compressing includes compressing a first cell stack and a second cell stack, wherein the inserting comprised inserting both the first cell stack and the second cell stack into the enclosure structure 
 compressing the first cell stack using a first compression fixture, and compressing the second cell stack using second compression fixture that is different than the first compression fixture, 
 wherein the first cell stack and the second cell stack are each disposed along a respective cell stack axis, and further comprising, prior to the inserting, pressing the first cell stack relatively toward the second cell stack. 
 
     
     
       15. The method of  claim 14 , further comprising pressing until the first compression fixture contacts the second compression fixture. 
     
     
       16. The method of  claim 14  wherein the pusher occupies the place of the at least one cell that is pushed out of the enclosure structure until at least one replacement cell is inserted into the cell-receiving opening of the enclosure structure. 
     
     
       17. The method of  claim 14 , wherein the enclosure structure is an enclosure halo.